High-rise self-supporting formwork building system

ABSTRACT

The present disclosure relates to components and methods for a modular building system, used for high-rise residential and office building, to pre-fabricate and assemble the system quickly, easily and simply. More particularly, it relates to a building temporary self-supporting panel system invention that includes formwork, structural rebars and insulated panels for the purpose of wall, floor and roof, also for the structure and enclosure. The building system is composed of a number of layers and a temporary-structural frame, integrating all constructive elements needed: temporary structural capacity, thermal and acoustical insulation, impermeability and pre-installations; designed considering operation, function, fabrication and assembling.

BACKGROUND

There are various types of building systems. In general, the most commonbuilding systems cannot satisfy the demands of industrialization and theneed of intelligent and smart construction.

One possible solution to the overall complexity and resourceinefficiency issues of traditional construction is the use ofprefabricated construction technologies. Generally, a prefabricatedsystem includes a primary framing structure and a secondary enclosure ofpanels, assembled on-site. Although there have been certain improvementsin prefabricated building construction systems, including panels, walls,buildings, methods of making building panels, methods of constructingwalls, wall systems and buildings systems, there are still unmet needsand a wide field of developments of more efficient and ambitioussystems. Prefabricated construction systems are increasingly common insingle-family home building, but are virtually absent at a large scalein high-rise building. This is primarily due to the difficulty andcomplexity of structure and equipment, the cost of investing in buildingfacilities, the risk of trying a new construction method, and thestartup cost of research and development.

There is a need in the construction industry for the necessaryimprovements in lightweight building panels and systems to reach ahigh-rise building with a clear and simple system that attends thedifferent needs of this typology. The present disclosure provides theart with a construction system that overcomes all the disadvantages ofthe previous systems and can fulfill the requirement of high-risebuilding.

SUMMARY

Some embodiments include a single, self-supporting and formwork panel,which behaves like a temporal structure. Said formwork is to be castedin concrete on-site, with division of space at the same time. Thus, astandard building system contains various construction elementsassembled on-site. Aspects of the disclosed subject matter include wallpanel, slab panel and truss/facade frame, that integrate allconstructive elements needed: structural capacity (once the steel-frameformwork is casted in concrete), thermal and acoustic insulation,impermeability, and pre-installations in a very efficient and flexiblemanner.

Some embodiments include a system having modular panels for simplifyingthe constructions of buildings and/or interior spaces, as well asmethods for using those panels to construct those buildings and/orinterior spaces. In some embodiments, the panels include a number offunctional layers to endow the panels with desired properties. In someembodiments, the panels provide buildings and interior spaces withwalls, floors, and ceilings. In some embodiments, the panels areconfigured to be lightweight for easier construction, assembly andconcreting.

In some embodiments, the panels have an internal structure. In someembodiments, the panels are self-supporting during construction works.In some embodiments, the internal structure includes both horizontal andvertical components. In some embodiments, the internal structureincludes the structural corrugated steel bars attached to the formworkas a reinforcement for the in-site cast concrete. In some embodiments,the internal structure profiles constitutes the formwork for the castconcrete. In some embodiments, panels include the structural corrugatedsteel bars attached to the formwork. In some embodiments, panels areconnectable to adjacent panels via the internal structure. In someembodiments, the internal structure includes extension areas configuredto interface with adjacent panels. In some embodiments, panels includerecessed areas for accepting the extensions of adjacent panels. In someembodiments, the internal structure includes longitudinal components. Insome embodiments, the internal structure is comprised of C and U shapedprofiles as temporal beams and joists. In some embodiments, internalstructure components are combined with fasteners, such as screws. Insome embodiments, adjacent panels are combined with such fasteners.

In some embodiments, the components of the internal structure defineinterior space within each panel. In some embodiments, the functionallayers are provided in the interior space. In some embodiments, thefunctional layers are a modular block sized to fit the interior spacesdefined by the modular internal structure and an outer layer.

In some embodiments, wall panels include at least one outer layerforming a side of the panel. In some embodiments, the internalstructure, comprised of C and U shaped profiles constituting theformwork for the on-site casted concrete. In some embodiments, wallpanels include the structural corrugated steel bars attached to theformwork. In some embodiments, wall panels include the structuralcorrugated steel bars attached to the formwork as a reinforcement forthe on-site casted concrete. In some embodiments, wall panels include atleast one acoustic insulation layer. In some embodiments, wall panelsinclude at least one filler layer. In some embodiments, the filler layeris a thermal insulating layer. The thickness of the wall panels is ofany desired size, and configured to connect to adjacent panels on atleast a horizontal axis and a vertical axis. In some embodiments, theouter layer is connected directly to the internal structure. In someembodiments, an additional outer layer is provided on the side oppositethe first outer layer of the wall panel.

In some embodiments, wall lintels include at least one outer layerforming a side of the panel. In some embodiments, the internalstructure, comprised of C and U shaped profiles, constitute the formworkfor the on-site casted concrete. In some embodiments, wall lintelsinclude the structural corrugated steel bars attached to the formwork.In some embodiments, wall lintels include at least one acousticinsulation layer. In some embodiments, wall lintels include at least onefiller layer. The thickness of the wall lintels is of any desired size,and configured to connect to adjacent panels. In some embodiments, theouter layer is connected directly to the internal structure. In someembodiments, an additional outer layer is provided on the side oppositeto the first outer layer of the wall lintel.

In some embodiments, floor and/or ceiling panel, referred to herein as“slab” panel, also include at least one outer layer, forming the side ofthe slab panel. In some embodiments, the internal structure, comprisedof C and U shaped profiles and the metal layer form the formwork for theon-site casted concrete for beams and joists. In some embodiments, themetal layer is a corrugated metal sheet. In some embodiments, the slabpanel includes the structural corrugated steel bars attached to theformwork.

In some embodiments, truss/facade panels, referred to herein as“truss/facade”, include at least one outer layer forming a side of thetruss/facade. In some embodiments, the internal structure, comprised ofC and U shaped profiles, constitutes the formwork for the on-site castedconcrete. In some embodiments, the truss/facade includes the structuralcorrugated steel bars attached to the formwork. The thickness of thetruss/facade is of any desired size, and configured to connect toadjacent panels. In some embodiments, the truss/facade includes at leasta curtain wall system. In some embodiments, the curtain wall system inthe aforementioned truss/facade frame is a fixed window or a panel. Insome embodiments, the fixed window serves as acoustic and thermalinsulation. In some embodiments, the truss/facade frame is the enclosureelement which satisfies the demand for illumination and ventilation. Insome embodiments, the truss/facade frame is connected with adjacent wallpanel, slab panel and truss/facade panel.

The panels of the present disclosure can be manufactured on an assemblyline and easily transported. The modular nature of the panels alsoenables advantageous quality control, cost reduction, waste reduction,improvement of working conditions for workers, use of specializedequipment, and reduction of construction times, complexity, and injuryrisk. Further, the panels provide for advantageous ductility andtolerances. The panels are assembled and casted in concrete in phases.The assembling phases correspond to the logic of construction, beingassembled by element and level.

The disclosure includes a plurality of elements, which is capable to beprefabricated and hoisted on-site. The elements in current disclosureinclude, but not limited to, the shaft cabinet element, stair elements,bath modules, kitchen module, elevators door module and technical floor.All the elements in the disclosure have internal structure and areself-supporting. In some embodiments, the element is prefabricated withplumbing, electrical and mechanical fixtures. In some embodiments, theinstallation fixture is prefabricated in a modular manner.

In some embodiments, elements include different types of interiorfunctional features of the building. In some embodiments, elements areprefabricated with the necessary features to be connected between eachother. In some embodiments, elements are prefabricated with thenecessary features to be connected with the building mechanical, pipingand electrical features. In some embodiments, elements satisfy thecomfort and usability needs of the building.

The elements of the present disclosure can be manufactured on anassembly line and easily transported. The modular nature of the elementsalso enables advantageous quality control, cost reduction, wastereduction, improvement of working conditions for workers, use ofspecialized equipment, and reduction of construction times, complexity,and injury risk. Further, the panels provide for advantageous ductilityand tolerances. The elements are assembled in phases. The assemblingphases correspond to the logic of construction, being assembled by leveland element.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1 is a front elevation of the wall panel “Bottom”, showing theinternal lightweight structure and the internal substructure formed bycold-formed steel profiles, consistent with some embodiments of thepresent disclosure;

FIG. 2 is a transversal section of the wall panel “Bottom”, consistentwith some embodiments of the present disclosure;

FIG. 3 is a front elevation of the wall panel “Bottom”, showing thefinishing panels, consistent with some embodiments of the presentdisclosure;

FIG. 4 is a plan-view cross-section of the wall panel “Bottom”, showingthe completed panel (internal lightweight structure, corrugated steelrebar, substructure and finishing), consistent with some embodiments ofthe present disclosure;

FIG. 5 is a top-view of the wall panel “Bottom”, showing the completedpanel (internal lightweight structure, corrugated steel rebars,substructure and finishing), consistent with some embodiments of thepresent disclosure;

FIG. 6 illustrates an axonometric view of the wall panel “Bottom”,showing the total volume of the panel, consistent with some embodimentsof the present disclosure;

FIG. 7 illustrates an axonometric view of the wall panel “Bottom”,showing the different exploded layers of the panels; consistent withsome embodiments of the present disclosure;

FIG. 8 is a front elevation of the wall panel “End Wall Bottom”, showingthe internal lightweight structure and the internal substructure formedby cold-formed steel profiles, consistent with some embodiments of thepresent disclosure;

FIG. 9 is a transversal section of the wall panel “End Wall Bottom”,consistent with some embodiments of the present disclosure;

FIG. 10 is a front elevation of the wall panel “End Wall Bottom”,showing the finishing panels, consistent with some embodiments of thepresent disclosure;

FIG. 11 is a plan-view cross-section of the wall panel “End WallBottom”, showing the completed panel (internal lightweight structure,corrugated steel rebar, substructure and finishing), consistent withsome embodiments of the present disclosure;

FIG. 12 is a top-view of the wall panel “End Wall Bottom”, showing thecompleted panel (internal lightweight structure, corrugated steelrebars, substructure and finishing), consistent with some embodiments ofthe present disclosure;

FIG. 13 illustrates an axonometric view of the wall panel “End WallBottom”, showing the total volume of the panel, consistent with someembodiments of the present disclosure;

FIG. 14 illustrates an axonometric view of the wall panel “End WallBottom”, showing the different exploded layers of the panels; consistentwith some embodiments of the present disclosure;

FIG. 15 is a front elevation of the wall panel “Top”, showing theinternal lightweight structure and the internal substructure formed bycold-formed steel profiles, consistent with some embodiments of thepresent disclosure;

FIG. 16 is a transversal section of the wall panel “Top”, consistentwith some embodiments of the present disclosure;

FIG. 17 is a front elevation of the wall panel “Top”, showing thefinishing panels, consistent with some embodiments of the presentdisclosure;

FIG. 18 is a plan-view cross-section of the wall panel “Top”, showingthe completed panel (internal lightweight structure, corrugated steelrebars, substructure and finishing), consistent with some embodiments ofthe present disclosure;

FIG. 19 is a top-view of the wall panel “Top”, showing the completedpanel (internal lightweight structure, corrugated steel rebars,substructure and finishing), consistent with some embodiments of thepresent disclosure;

FIG. 20 illustrates an axonometric view of the wall panel “Top”, showingthe total volume of the panel, consistent with some embodiments of thepresent disclosure;

FIG. 21 illustrates an axonometric view of the wall panel “Top”, showingthe different exploded layers of the panels, consistent with someembodiments of the present disclosure;

FIG. 22 is a front elevation of the wall panel “Top w/Opening”, showingthe internal lightweight structure and the internal substructure formedby cold-formed steel profiles, consistent with some embodiments of thepresent disclosure;

FIG. 23 is a transversal section of the wall panel “Top w/Opening”,consistent with some embodiments of the present disclosure;

FIG. 24 is a front elevation of the wall panel “Top w/Opening”, showingthe finishing panels, consistent with some embodiments of the presentdisclosure;

FIG. 25 is a plan-view cross-section of the wall panel “Top w/Opening”,showing the completed panel (internal lightweight structure, corrugatedsteel rebars, substructure and finishing), consistent with someembodiments of the present disclosure;

FIG. 26 is a top-view of the wall panel “Top w/Opening”, showing thecompleted panel (internal lightweight structure, corrugated steelrebars, substructure and finishing), consistent with some embodiments ofthe present disclosure;

FIG. 27 illustrates an axonometric view of the wall panel “Topw/Opening”, showing the total volume of the panel, consistent with someembodiments of the present disclosure;

FIG. 28 illustrates an axonometric view of the wall panel “Topw/Opening”, showing the different exploded layers of the panels;consistent with some embodiments of the present disclosure;

FIG. 29 is a front elevation of the wall “lintel”, showing the internallightweight structure and the internal substructure formed bycold-formed steel profiles, consistent with some embodiments of thepresent disclosure;

FIG. 30 is a transversal section of the wall “lintel”, consistent withsome embodiments of the present disclosure;

FIG. 31 is a front elevation of the wall “lintel”, showing the finishingpanels, consistent with some embodiments of the present disclosure;

FIG. 32 is a plan-view cross-section of the wall “lintel”, showing thecompleted panel (internal lightweight structure, substructure andfinishing), consistent with some embodiments of the present disclosure;

FIG. 33 illustrates an axonometric view of the wall “lintel”, showingthe total volume of the panel, consistent with some embodiments of thepresent disclosure;

FIG. 34 illustrates an axonometric view of the wall “lintel”, showingthe different exploded layers of the panel; consistent with someembodiments of the present disclosure;

FIG. 35 is a top view of the slab panel “Unit”, showing the internallightweight structure and formwork constituted by cold-formed steelprofiles, consistent with some embodiments of the present disclosure;

FIG. 36 is an elevation view cross-section of the slab panel “Unit”,showing the completed panel with the different layers, consistent withsome embodiments of the present disclosure;

FIG. 37 is a top view of the slab panel “Unit”, showing the completedslab including corrugated steel sheets and the attached corrugated steelrebars, consistent with some embodiments of the present disclosure;

FIG. 38 is an elevation-view transversal-section of the slab panel“Unit”, showing the material layers and the internal structure,consistent with some embodiments of the present disclosure;

FIG. 39 illustrates an axonometric view of the slab panel “Unit”,showing the internal prefabricated structure of steel profiles andcorrugated steel bars, consistent with some embodiments of the presentdisclosure;

FIG. 40 illustrates an axonometric view of the slab panel “Unit”,showing the total volume of the panel, consistent with some embodimentsof the present disclosure;

FIG. 41 illustrates an axonometric view of the slab panel “Unit”,showing the exploded different layers of the panels, consistent withsome embodiments of the present disclosure;

FIG. 42 is a front elevation of the truss/facade “Core Bottom”, showingthe internal lightweight structure formed by cold-formed steel profilesand the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 43 is a transversal section of the truss/facade “Core Bottom”,consistent with some embodiments of the present disclosure;

FIG. 44 is a front elevation of the truss/facade “Core Bottom”, showingthe internal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 45 is a top-view of the truss/facade “Core Bottom”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 46 is a plan-view cross-section of the truss/facade “Core Bottom”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 47 illustrates an axonometric view of the truss/facade “CoreBottom”, showing the internal lightweight structure and corrugated steelbars, consistent with some embodiments of the present disclosure;

FIG. 48 illustrates an axonometric view of the truss/facade “CoreBottom”, showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 49 illustrates an axonometric view of the truss/facade “CoreBottom”, showing the different exploded layers of the panels; consistentwith some embodiments of the present disclosure;

FIG. 50 is a front elevation of the truss/facade “Core Top”, showing theinternal lightweight structure formed by cold-formed steel profiles andthe attached corrugated steel rebars, consistent with some embodimentsof the present disclosure;

FIG. 51 is a transversal section of the truss/facade “Core Top”,consistent with some embodiments of the present disclosure;

FIG. 52 is a front elevation of the truss/facade “Core Top”, showing theinternal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 53 is a top-view of the truss/facade “Core Top”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 54 is a plan-view cross-section of the truss/facade “Core Top”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 55 illustrates an axonometric view of the truss/facade “Core Top”,showing the internal lightweight structure and corrugated steel bars,consistent with some embodiments of the present disclosure;

FIG. 56 illustrates an axonometric view of the truss/facade “Core Top”,showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 57 illustrates an axonometric view of the truss/facade “Core Top”,showing the different exploded layers of the panels; consistent withsome embodiments of the present disclosure;

FIG. 58 is a front elevation of the truss/facade “Long Bottom”, showingthe internal lightweight structure formed by cold-formed steel profilesand the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 59 is a transversal section of the truss/facade “Long Bottom”,consistent with some embodiments of the present disclosure;

FIG. 60 is a front elevation of the truss/facade “Long Bottom”, showingthe internal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 61 is a top-view of the truss/facade “Long Bottom”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 62 is a plan-view cross-section of the truss/facade “Long Bottom”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 63 illustrates an axonometric view of the truss/facade “LongBottom”, showing the internal lightweight structure and corrugated steelbars, consistent with some embodiments of the present disclosure;

FIG. 64 illustrates an axonometric view of the truss/facade “LongBottom”, showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 65 illustrates an axonometric view of the truss/facade “LongBottom”, showing the different exploded layers of the panels, consistentwith some embodiments of the present disclosure;

FIG. 66 is a front elevation of the truss/facade “Long Top”, showing theinternal lightweight structure formed by cold-formed steel profiles andthe attached corrugated steel rebars, consistent with some embodimentsof the present disclosure;

FIG. 67 is a transversal section of the truss/facade “Long Top”,consistent with some embodiments of the present disclosure;

FIG. 68 is a front elevation of the truss/facade “Long Top”, showing theinternal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 69 is a top-view of the truss/facade “Long Top”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 70 is a plan-view cross-section of the truss/facade “Long Top”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 71 illustrates an axonometric view of the truss/facade “Long Top”,showing the internal lightweight structure and corrugated steel bars,consistent with some embodiments of the present disclosure;

FIG. 72 illustrates an axonometric view of the truss/facade “Long Top”,showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 73 illustrates an axonometric view of the truss/facade “Long Top”,showing the different exploded layers of the panels, consistent withsome embodiments of the present disclosure;

FIG. 74 is a front elevation of the truss/facade “Short Bottom”, showingthe internal lightweight structure formed by cold-formed steel profilesand the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 75 is a transversal section of the truss/facade “Short Bottom”,consistent with some embodiments of the present disclosure;

FIG. 76 is a front elevation of the truss/facade “Short Bottom”, showingthe internal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 77 is a top-view of the truss/facade “Short Bottom”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 78 is a plan-view cross-section of the truss/facade “Short Bottom”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 79 illustrates an axonometric view of the truss/facade “ShortBottom”, showing the internal lightweight structure and corrugated steelbars, consistent with some embodiments of the present disclosure;

FIG. 80 illustrates an axonometric view of the truss/facade “ShortBottom”, showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 81 illustrates an axonometric view of the truss/facade “ShortBottom”, showing the different exploded layers of the panels, consistentwith some embodiments of the present disclosure;

FIG. 82 is a front elevation of the truss/facade “Short Top”, showingthe internal lightweight structure formed by cold-formed steel profilesand the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 83 is a transversal section of the truss/facade “Short Top”,consistent with some embodiments of the present disclosure;

FIG. 84 is a front elevation of the truss/facade “Short Top”, showingthe internal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 85 is a top-view of the truss/facade “Short Top”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 86 is a plan-view cross-section of the truss/facade “Short Top”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 87 illustrates an axonometric view of the truss/facade “Short Top”,showing the internal lightweight structure and corrugated steel bars,consistent with some embodiments of the present disclosure;

FIG. 88 illustrates an axonometric view of the truss/facade “Short Top”,showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 89 illustrates an axonometric view of the truss/facade “Short Top”,showing the different exploded layers of the panels, consistent withsome embodiments of the present disclosure;

FIG. 90 is a front elevation of the truss/facade “100X34 Bottom”,showing the internal lightweight structure formed by cold-formed steelprofiles and the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 91 is a transversal section of the truss/facade “100X34 Bottom”,consistent with some embodiments of the present disclosure;

FIG. 92 is a front elevation of the truss/facade “100X34 Bottom”,showing the internal substructure formed by cold-formed steel profilesand the window panels, consistent with some embodiments of the presentdisclosure;

FIG. 93 is a top-view of the truss/facade “100X34 Bottom”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 94 is a plan-view cross-section of the truss/facade “100X34Bottom”, showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 95 illustrates an axonometric view of the truss/facade “100X34Bottom”, showing the internal lightweight structure and corrugated steelbars, consistent with some embodiments of the present disclosure;

FIG. 96 illustrates an axonometric view of the truss/facade “100X34Bottom”, showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 97 illustrates an axonometric view of the truss/facade “100X34Bottom”, showing the different exploded layers of the panels, consistentwith some embodiments of the present disclosure;

FIG. 98 is a front elevation of the truss/facade “100X34 Top”, showingthe internal lightweight structure formed by cold-formed steel profilesand the attached corrugated steel rebars, consistent with someembodiments of the present disclosure;

FIG. 99 is a transversal section of the truss/facade “100X34 Top”,consistent with some embodiments of the present disclosure;

FIG. 100 is a front elevation of the truss/facade “100X34 Top”, showingthe internal substructure formed by cold-formed steel profiles and thewindow panels, consistent with some embodiments of the presentdisclosure;

FIG. 101 is a top-view of the truss/facade “100X34 Top”, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 102 is a plan-view cross-section of the truss/facade “100X34 Top”,showing the completed element (internal lightweight structure,corrugated steel bars, substructure and window panels), consistent withsome embodiments of the present disclosure;

FIG. 103 illustrates an axonometric view of the truss/facade “100X34Top”, showing the internal lightweight structure and corrugated steelbars, consistent with some embodiments of the present disclosure;

FIG. 104 illustrates an axonometric view of the truss/facade “100X34Top”, showing the total volume of the element, consistent with someembodiments of the present disclosure;

FIG. 105 illustrates an axonometric view of the truss/facade “100X34Top”, showing the different exploded layers of the panels, consistentwith some embodiments of the present disclosure;

FIG. 106 is a transversal cross-section of the “Shaft Cabinet” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 107 is a front elevation of the “Shaft Cabinet” element, showingthe completed element, consistent with some embodiments of the presentdisclosure;

FIG. 108 is a plan-view cross-section of the “Shaft Cabinet” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 109 illustrates an axonometric view of the “Shaft Cabinet” element;consistent with some embodiments of the present disclosure;

FIG. 110 is a transversal cross-section of the “Stair Type 1” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 111 is a front elevation of the “Stair Type 1” element, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 112 is a plan-view cross-section of the “Stair Type 1” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 113 illustrates an axonometric view of the “Stair Type 1” element,consistent with some embodiments of the present disclosure;

FIG. 114 is a transversal cross-section of the “Stair Type 2” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 115 is a front elevation of the “Stair Type 2” element, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 116 is a plan-view cross-section of the “Stair Type 2” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 117 illustrates an axonometric view of the “Stair Type 2” element,consistent with some embodiments of the present disclosure;

FIG. 118 is a transversal cross-section of the “Bath Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 119 is a front elevation of the “Bath Module” element, showing thecompleted element, consistent with some embodiments of the presentdisclosure;

FIG. 120 is a plan-view cross-section of the “Bath Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 121 illustrates an axonometric view of the “Bath Module” element,consistent with some embodiments of the present disclosure;

FIG. 122 is a transversal cross-section of the “Bath Common Module”element, showing the completed element, consistent with some embodimentsof the present disclosure;

FIG. 123 is a front elevation of the “Bath Common Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 124 is a plan-view cross-section of the “Bath Common Module”element, showing the completed element, consistent with some embodimentsof the present disclosure;

FIG. 125 illustrates an axonometric view of the “Bath Common Module”element, consistent with some embodiments of the present disclosure;

FIG. 126 is a transversal cross-section of the “Kitchen Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 127 is a front elevation of the “Kitchen Module” element, showingthe completed element, consistent with some embodiments of the presentdisclosure;

FIG. 128 is a plan-view cross-section of the “Kitchen Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 129 illustrates an axonometric view of the “Kitchen Module”element, consistent with some embodiments of the present disclosure;

FIG. 130 is a transversal cross-section of the “Elevators Doors Module”element, showing the completed element, consistent with some embodimentsof the present disclosure;

FIG. 131 is a front elevation of the “Elevators Doors Module” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 132 is a plan-view cross-section of the “Elevators Doors Module”element, showing the completed element, consistent with some embodimentsof the present disclosure;

FIG. 133 illustrates an axonometric view of the “Elevators Doors Module”element, consistent with some embodiments of the present disclosure;

FIG. 134 is a transversal cross-section of the “Core Technical Floor”element, showing the completed element, consistent with some embodimentsof the present disclosure;

FIG. 135 is a front elevation of the “Core Technical Floor” element,showing the completed element, consistent with some embodiments of thepresent disclosure;

FIG. 136 is a top-view of the “Core Technical Floor” element, showingthe completed element, consistent with some embodiments of the presentdisclosure;

FIG. 137 illustrates an axonometric view of the “Core Technical Floor”element; consistent with some embodiments of the present disclosure;

FIG. 138 illustrates an axonometric view of a typical casted in concretelevel of “Construction Module100X50”, showing the optimal application ofthe building system; consistent with some embodiments of the presentdisclosure;

FIG. 139 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of the wall panels“Bottom”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 140 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of the trusses/facades“Bottom”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 141 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of all the differentconstruction elements, showing the optimal application of the buildingsystem, consistent with some embodiments of the present disclosure;

FIG. 142 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the casted in concrete phase of“Bottom” parts, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 143 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of the wall panels “Top”,showing the optimal application of the building system, consistent withsome embodiments of the present disclosure;

FIG. 144 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of the trusses/facades“Top”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 145 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of lintels and all thedifferent construction elements, showing the optimal application of thebuilding system, consistent with some embodiments of the presentdisclosure;

FIG. 146 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the addition of “Slab” panels, showingthe optimal application of the building system, consistent with someembodiments of the present disclosure;

FIG. 147 illustrates an axonometric view of a typical level of“Construction Module100X50”, with the casted in concrete phase of “Top”parts, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 148 illustrates an axonometric view of a typical casted in concretelevel of “Construction Module100X34”, showing the optimal application ofthe building system, consistent with some embodiments of the presentdisclosure;

FIG. 149 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of the wall panels“Bottom”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 150 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of the trusses/facades“Bottom”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 151 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of all the differentconstruction elements, showing the optimal application of the buildingsystem, consistent with some embodiments of the present disclosure;

FIG. 152 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the casted in concrete phase of“Bottom” parts, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 153 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of the wall panels “Top”,showing the optimal application of the building system, consistent withsome embodiments of the present disclosure;

FIG. 154 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of the trusses/facades“Top”, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

FIG. 155 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of all the differentconstruction elements, showing the optimal application of the buildingsystem, consistent with some embodiments of the present disclosure;

FIG. 156 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the addition of “Slab” panels, showingthe optimal application of the building system, consistent with someembodiments of the present disclosure;

FIG. 157 illustrates an axonometric view of a typical level of“Construction Module100X34”, with the casted in concrete phase of “Top”parts, showing the optimal application of the building system,consistent with some embodiments of the present disclosure;

DESCRIPTION

The standard building system of the present disclosure contains variousconstruction elements assembled on-site, aspects of the disclosedsubject matter include different categories of panels: four categoriesof wall panels, one category of wall lintel, one category of slab paneland eight categories of truss/facade.

The standard building system of the present disclosure contains variousprefabricated elements assembled on-site, aspects of the disclosedsubject matter include different categories of elements: one category ofshaft cabinet element, two category of stairs, two categories of bathmodules, one category of kitchen module, one category of elevators doorsmodule and one category of technical floor.

In some embodiments, a plurality of wall panels is provided as a kitwherein the plurality of the wall panels is of the same type. In someembodiments, a plurality of wall panels is provided as a kit, whereinwall panels come in a plurality of different types. In some embodiments,four different types are complementary in denomination, i.e., the wallpanels could come in four types: a type with a door opening, a typewithout opening, a type with a closed end and a type with an openingwithout door. The size of each type of the wall panel is ultimately thedecision of the user and depends upon the following non-limiting list offactors: human-scale, space quality, industrial sizes, andtransportation margins.

Referring to FIG. 1, in some embodiments, the wall panels “Bottom” forusing with the system of the present disclosure have internal structuresconfigured to operate as a support skeleton. In some embodiments, themain internal structure is comprised of columns U-profiles 5 andC-profiles 6 which is configured as the formwork for in-site castedconcrete. Referring to FIGS. 1, 4 and 5, secondary structure 15 iscomposed by C-profiles 4 and U-profiles 3. In some embodiments thesecondary structure 15 referring to FIGS. 1 and 4 support the functionallayer 19. Referring to FIGS. 2, 3 and 4, functional layer 19 comprises athermal and acoustic insulation 14 and sideboard 13. In someembodiments, the panels are self-supporting during construction work. Insome embodiments, the panels have a vertical crush resistance of atleast 2000 pounds per linear foot; length of said wall panel when testedaccording to ASTM E72, and using a safety factor of 3. In someembodiments, the panels have a bending resistance when subjected touniform loading in accord with ASTM E72 of up to 2000 pounds per squarefoot surface area.

In some embodiments, panels are configured to be connected to otherpanels and/or a building foundation. In some embodiments, theconnections are made via the internal structures of adjacent panels andvia rebars 17. In some embodiments, the connection between the variouspanels and/or the connection between the panels and the foundation isreversible. In some embodiments, panels are connected directly to afoundation using any suitable means. In some embodiments, an interfaceis provided to stabilize the connection between a panel and thefoundation.

Referring to FIGS. 1-7, 1 wall panels “Bottom” 57 is provided. Referringto FIG. 5, in some embodiments, U-profile 5 and C-profile 6 constitutethe steel frame and act as the formwork 18 for in-site casted concrete16. In some embodiments the steel frame comprises rebars 17 that allowfor connection with panels installed above them, as will be discussed inthe construction process below. In some embodiments wall panels areconnected with other wall panels “Bottom” 57. In some embodiments wallpanels are connected with other wall panels “Top” 72. In someembodiments wall panels are connected with slab panel unit 79. In someembodiments panels are connected with truss/facade “Core Bottom” 59. Insome embodiments panels are connected with truss/facade “Core Top” 74.

Referring again to FIGS. 3-4, the wall panel includes at least twosideboards 13. In some embodiments, side boards are disposed on opposingsides of the interior space of wall panel. In some embodiments, sideboards are comprised of at least one of wood, cement, fiber cement,drywall, suitable metal sheets, and the like. In some embodiments, thethickness of sideboards 13 is approximately 0.5-1 inches.

In some embodiments, wall panel further includes at least one acousticinsulation layer (such as Rockwool) 14. In some embodiments, thethickness and composition of Rockwool are configured to provide thedesired level of sound insulation to wall panel. In some embodiments,the thickness of Rockwool is approximately 45-50 mm (2 inch) in eachside. In some embodiments, the Rockwool is filled in the inner space ofsubstructure 15.

The overall thickness of wall panel is the summation of at least thelayers described in the above paragraphs. In some embodiments, theoverall thickness of wall panel is adapted according to local needs,such as climate conditions, building codes, constructions budget, andthe like. In some embodiments, the total thickness of wall panel isapproximately 32½ inches. In some embodiments, this thickness includesthe internal structure. In some embodiments, the main internal structureis disposed between functional layers 19 and the substructure isdisposed between formwork 18 and the sideboard 13.

In some embodiments, the wall panels have internal structure. In someembodiments, the internal structure includes a main structure and asubstructure. In some embodiments, the main structure comprises someprofiles such as U-profile 5 and C-profiles 4. In some embodiments, themain structure serves as formwork 18 for on-site casted concrete 16. Insome embodiments, a plurality of prefabricated rebars 17 is contained inthe formwork 18 for the possible connection to the upper panels. In someembodiments, the distance between two sides of the formwork 18 is 24inches.

In some embodiments, the formwork 18 is held and fastened by onesubstructure 15 on each side. In some embodiments, any other functionallayer 19 disposed are held between profiles such as U-profiles 3 andC-profiles 4 from FIG. 7. In some embodiments, these profiles formsubstructure 15 of panel. In some embodiments, the horizontal distancebetween two C-profiles 4 in the substructure is 2 feet. In someembodiments, the profiles in substructure along with the functionallayers held there between defines a functional layer block that can bestacked with other functional layer blocks to fill the interior space ofa panel. In some embodiments, two functional layer blocks are attachedon both side of the structural formwork 18.

Referring to FIGS. 3, 4 and 6, the wall panel integrates a door 20. Insome embodiments, the door 20 is a double flush door. In someembodiments, the door 20 is directly connected to the substructure 15.

Referring to FIGS. 8-14, the wall panels “End Bottom” 58 havesimilarities in internal structure, layers and differences in thestructural opening and in the finished dimensions. In some embodiments,the internal structure of wall comprises profiles which form the mainstructural formwork 18. In some embodiments, substructures withfunctional layers are installed on both side of formwork 18 like thewall panel “Bottom” 57. In some embodiments, the components and order offunctional layers in the wall panels “End Bottom” 58 are the same asthose in wall panels “Bottom” 57.

Referring to FIGS. 15-21, the wall panels “Top” 72 have similarities ininternal structure, layers and differences in the structural opening andin the finished dimensions. In some embodiments, the internal structureof wall comprises profiles which form the main structural formwork 18.In some embodiments, substructures with functional layers are installedon both side of formwork 18 like the wall panel “Bottom” 57. In someembodiments, the components and order of functional layers in the wallpanels “Top” 72 are the same as those in wall panels “Bottom” 57.

Referring to FIGS. 22-28, the wall panels “Top w/Opening” 73 havesimilarities in internal structure, layers and differences in thestructural opening and in the finished dimensions. In some embodiments,the wall panels “Top w/Opening” 73 integrate a structural opening 21. Insome embodiments, the internal structure of wall comprises profileswhich form the main structural formwork 18. In some embodiments,substructures with functional layers are installed on both side offormwork 18 like the wall panel “Bottom” 57. In some embodiments, thecomponents and order of functional layers in the wall panels “Topw/Opening”73 are the same as those in wall panels “Bottom” 57.

Referring to FIGS. 29-34, the wall “lintel” 78 have similarities ininternal structure, layers and differences in the structural dimensions.In some embodiments, the internal structure of wall comprises profileswhich form the main structural formwork 18. In some embodiments,substructures with functional layers are installed on both side offormwork 18 like the wall panel “Bottom” 57. In some embodiments, thecomponents and order of functional layers in the wall “lintel” 78 arethe same as those in wall panels “Bottom” 57.

Referring to FIGS. 35-41, in some embodiments, a slab panel is provided:“Slab Panel Unit” 79. In some embodiments, slab panels unit areapproximately 8′ 0″ in width and approximately 39′ 0″ in length. In someembodiments, slab panels unit are approximately 8′ 0″ in width andapproximately 32′ 0″ in length. The size of slab panel is ultimately thedecision of the user and depends upon the following non-limiting list offactors: structure feasibility, building code, human-scale, spacepossibility, industrial sizes, and transportation margins. In someembodiments, the slab panels have steel frame as seen in FIG. 37. Insome embodiments, the steel frame includes an internal structure whichare formed by steel profiles groups 22 which have a C-profile 2 jammedin a U-profile 1. In some embodiment, the internal structure is dividedinto five modules. In some embodiment a U-profiles 23 are connected onthe periphery of the internal structure as the bottom of formwork foron-site casted concrete 26. In some embodiment a transversal U-profile24 is connected between two parts as bottom of formwork for on-sitecasted concrete 26. Referring to FIGS. 36-38, in some embodiment, aplurality of metal corrugated sheet 25 are fixed upon the internalstructure served as the formwork 28 of on-site casted concrete 26. Insome embodiments, metal corrugated sheet 25 has a thickness ofapproximately 2-3 inches (54 mm). In some embodiments the steel framecomprises prefabricated rebars 27. Referring to FIG. 39-41, in someembodiment, the steel rebars could be attached on the slab panel andcasted in concrete with the internal structure and profiles in-between.In some embodiment, the steel rebars in the slab panel could fasten withthe rebars on wall panel. In some embodiments, the rebars could becasted in concrete on either side. In some embodiments, concrete 26could cover the metal corrugated sheet 25 and the rebars 27 of slabpanel.

Referring to FIGS. 42-49, in some embodiments, the truss/facade “CoreBottom” 59 for use with the system of the present disclosure have astructure configured to operate as a support skeleton. Referring to FIG.42, in some embodiments, the main internal structure is composed bycolumns 33, diagonals 34 and horizontal 35. In some embodiments columns33, diagonals 34 and horizontal 35 are comprised of U-profiles 7 andC-profiles 8 which is configured as the formwork of on-site castedconcrete 30. In some embodiments, the secondary structure 36 referringto FIG. 44 integrate constructive elements needed such as steel frame,exterior curtain wall system 29 with window 37 and panel 38. In someembodiments, the trusses are self-supporting during construction work.In some embodiments, the panels have a vertical crush resistance of atleast 2000 pounds per linear foot; length of said wall panel when testedaccording to ASTM E72, and using a safety factor of 3. In someembodiments, the trusses have a bending resistance when subjected touniform loading in accord with ASTM E72 of up to 2000 pounds per squarefoot surface area.

As shown in FIGS. 42-46, the internal structures component of thetrusses provide space for the application of functional layers to endoweach panel with not only structural stability, but desired propertiesderived from the composition of materials filling that space. In someembodiments, the panels can have different interior spaces based on thepurpose of the panel and the needs of the system user. Some embodimentsare discussed below in FIGS. 47-49.

In some embodiments, trusses are configured to be connected to otherpanels. In some embodiments, the connections are made via the internalstructures of adjacent panels and via rebars 81. Referring to FIGS.42-46, in some embodiments, U-profile 7 and C-profile 8 constitute thesteel frame and act as the formwork 32 for on-site casted concrete 30.In some embodiments the steel frame comprises main rebars 31 and otherrebars 81 that allow for connection with truss/facade “Core Top” 74installed above them, as will be discussed in the construction processbelow. In some embodiments the profile 9 enables the connection withtruss/facade “Core Top” 74 installed above them. In some embodimentstruss panels are connected with possible wall panels 57, 72. In someembodiments truss panels are connected with possible slab panel unit 79.In some embodiments panels are connected with possible truss/facadepanels 60, 74.

Referring again to FIGS. 47-49, the truss/facade panel includes at leasta main internal structure. In some embodiments, main internal structureis composed by columns 33, diagonals 34 and horizontal beams 35. In someembodiments, columns, diagonals and horizontal are composed by U-profile7 and C-profile 8. In some embodiments, main internal structure isconfigured as the formwork 32 of on-site casted concrete 20. In someembodiments, formwork 32 comprises main rebars 31 and other rebars 81for structural connection.

In some embodiments, the truss/facade panel includes at least asubstructure 36. In some embodiments, the substructure 36 is composed byU-profile 11 and C-profile 12. In some embodiments, a U-profile 9 isfastened to the substructure 36 to enable connection with other panels.In some embodiments, the substructure 36 is configured to operate as asupport skeleton for the curtain wall system 29.

In some embodiments, truss/facade panel further includes an exteriorcurtain wall system 29 disposed on interior side. In some embodiments,curtain wall system 29 comprised of at least a window 37 and a panel 38.In some embodiments, window and panel can be customized according tocode, climate needs and user like. In some embodiments, curtain wallsystem 29 is supported to internal substructure 36.

The overall thickness of truss/facade panel is the summation of at leastthe layers described in the above paragraphs. In some embodiments, theoverall thickness of truss/facade panel is adapted according to localneeds, such as climate conditions, building codes, constructions budget,and the like. In some embodiments, the thickness is 24 inches.

Referring to FIGS. 50-57, the truss/facade “Core Top” 74 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Bottom”59. In some embodiments, a profile 10 is fastened to the substructure 36to enable connection with other panels. In some embodiments, thecomponents and other elements in the truss “Core Top” 74 are the same asthose in trusses “Core Bottom” 59.

Referring to FIGS. 58-65, the truss/facade “Long Bottom” 60 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Bottom”59. In some embodiments, a profile 9 is fastened to the substructure 36to enable connection with other panels. In some embodiments, thecomponents and order elements in the truss “Long Bottom” 60 are the sameas those in trusses “Core Bottom” 59.

Referring to FIGS. 66-73, the truss/facade “Long Top” 75 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Top” 74.In some embodiments, a profile 10 is fastened to the substructure 35 toenable connection with other panels. In some embodiments, the componentsand order elements in the truss “Long Top” 75 are the same as those intrusses “Core Top” 74.

Referring to FIGS. 74-81, the truss/facade “Short Bottom” 61 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Bottom”59. In some embodiments, a profile 9 is fastened to the substructure 36to enable connection with other panels. In some embodiments, thecomponents and order elements in the truss “Short Bottom” 61 are thesame as those in trusses “Core Bottom” 59.

Referring to FIGS. 82-89, the truss/facade “Short Top” 76 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Top” 74.In some embodiments, a profile 10 is fastened to the substructure 36 toenable connection with other panels. In some embodiments, the componentsand order elements in the truss “Short Top” 76 are the same as those intrusses “Core Top” 74.

Referring to FIGS. 90-97, the truss/facade “100X34 Bottom” 62 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Bottom”59. In some embodiments, a profile 10 is fastened to the substructure 36to enable connection with other panels. In some embodiments, thecomponents and order elements in the truss “100X34 Bottom” 62 are thesame as those in trusses “Core Bottom” 59.

Referring to FIGS. 98-105, the truss/facade “100X34 Top” 77 hassimilarities in internal structure, layers and differences in thestructural dimensions and in the dimension of the structural elements.In some embodiments, the internal structure of truss comprises columns,diagonals and horizontal which forms the main structural formwork 32. Insome embodiments, substructure 36 and curtain wall system 29 areinstalled on interior side of formwork 32 like the truss “Core Top” 74.In some embodiments, a profile 10 is fastened to the substructure 36 toenable connection with other panels. In some embodiments, the componentsand order elements in the truss “100X34 Top” 77 are the same as those intrusses “Core Top” 74.

In some embodiments, a plurality of prefabricated elements is providedas a kit wherein the plurality of the elements is of the same type. Insome embodiments, a plurality of elements is provided as a kit, whereinprefabricated elements come in a plurality of different types. In someembodiments, these different types are complementary in denomination.The size of each type of the elements is ultimately the decision of theuser and depends upon the following non-limiting list of factors:human-scale, space quality, industrial sizes, and transportationmargins.

Referring to FIG. 106-109, a “Shaft Cabinet” 65 is provided as aprefabricated element. In some embodiments, the shaft cabinet is 20′ 0″in length, 7′ 2″ in width and approximately 8′ 6″ in height. In someembodiments, the shaft cabinet includes a plurality of non-structuralself-supporting walls. In some embodiments, the walls of shaft cabinetinclude an internal structure and at least one functional layer 39. Insome embodiments, the functional layer 39 includes thermal and acousticthermal insulation 41 and cement board as finishing layer 40, similar asthe functional layer in wall panels. In some embodiments, the internalstructure is comprised of C-profiles 44 and U-profiles 45. In someembodiments, two installation cabinets and two doors 46 are integratedin the shaft cabinet. In some embodiments, the shaft cabinets includethe floor steel structure, comprised of C-profiles 44, U-Profiles 45 andcorrugated metal sheet 43. In some embodiments, the piping 47, ducts 48or conduits 49 correspondent to the installation are partly hold in thefunctional layer and partly fixed in the installation cabinet. In someembodiments the installation cabinet is accessible via a cabinet door46. In some embodiments, two access door 52 are integrated in the wallsof the “Shaft Cabinet” 65 elements. In some embodiments, the “ShaftCabinet” element includes a corrugated metal sheet 43 for the on-sitecasted concrete in the construction process. The shaft cabinet can beapplied in construction modules, as seen in FIGS. 138-157.

Referring to FIG. 110-113, a “Stair Type 1” 63 is provided as aprefabricated element. In some embodiments, the “Stair Type 1” elementis 20′ 0″ in length, 4′ 4″ in width and approximately 8′ 6″ in height.In some embodiments, the “Stair Type 1” element includes a plurality ofnon-structural self-supporting walls. In some embodiments, the walls of“Stair Type 1” element include an internal structure and at least onefunctional layer 39. In some embodiments, the functional layer 39includes thermal and acoustic insulation 41 and cement board asfinishing layer 39, similar as the functional layer in wall panel. Insome embodiments, the internal structure is comprised of C-profiles 44and U-profiles 45. In some embodiments, one prefabricated stair isintegrated in the “Stair Type 1” element. In some embodiments, theprefabricated stair is composed of a plurality of prefabricated steps 50and prefabricated landing 51. The “Stair Type 1” element can be appliedin construction modules, as seen in FIGS. 138-157.

Referring to FIG. 114-117, a “Stair Type 2” 64 is provided as aprefabricated element. In some embodiments, the “Stair Type 2” elementis 20′ 0″ in length, 4′ 4″ in width and approximately 8′ 6″ in height.In some embodiments, the “Stair Type 2” element includes a plurality ofnon-structural self-supporting walls. In some embodiments, the walls of“Stair Type 2” element include an internal structure and at least onefunctional layer 39. In some embodiments, the functional layer 39includes thermal and acoustic insulation and cement board as finishinglayer 40, similar as the functional layer in wall panel. In someembodiments, the internal structure is comprised of C-profiles 44 andU-profiles 45. In some embodiments, two access door 52 are integrated inthe walls of the “Stair Type 2” element. In some embodiments, oneprefabricated stair is integrated in the “Stair Type 2” element. In someembodiments, the prefabricated stair is composed of a plurality ofprefabricated steps 50 and prefabricated landing 51. The “Stair Type 2”element can be applied in construction modules, as seen in FIGS.138-157.

Referring to FIG. 118-121, a “Bath Module” 66 is provided as aprefabricated element. In some embodiments, the bath module is 15′ 3″ inlength, 9′ 0″ in width and approximately 7′ 6″ in height. In someembodiments, the bath module includes a plurality of non-structuralself-supporting walls. In some embodiments, the walls of bath moduleinclude an internal structure and at least one functional layer 39. Insome embodiments, the functional layer 39 includes thermal and acousticthermal insulation 41 and cement board as finishing layer 40, similar asthe functional layer in wall panels. In some embodiments, the internalstructure is comprised of C-profiles 44 and U-profiles 45. In someembodiments, plumbing fixtures 53 are integrated in the bath module. Insome embodiments, the piping 47 correspondent to the installation arepartly hold in the functional layer and partly fixed in the installationcabinet. In some embodiments the bath module is accessible via a door52. In some embodiments, three access door 52 are integrated in thewalls of the “Bath Module” 66 element. The shaft cabinet can be appliedin construction modules, as seen in FIGS. 138-157.

Referring to FIG. 122-125, a “Bath Common Module” 67 is provided as aprefabricated element. In some embodiments, the bath common module is10′ 0″ in length, 4′ 0″ in width and approximately 7′ 6″ in height. Insome embodiments, the bath common module includes a plurality ofnon-structural self-supporting walls. In some embodiments, the walls ofbath common module include an internal structure and at least onefunctional layer 39. In some embodiments, the functional layer 39includes thermal and acoustic thermal insulation 41 and cement board asfinishing layer 40, similar as the functional layer in wall panels. Insome embodiments, the internal structure is comprised of C-profiles 44and U-profiles 45. In some embodiments, plumbing fixtures 53 areintegrated in the bath common module. In some embodiments, the piping 47correspondent to the installation are hold in the functional layer. Thebath common module can be applied in construction modules, as seen inFIGS. 138-157.

Referring to FIG. 126-129, a “Kitchen Module” 68 is provided as aprefabricated element. In some embodiments, the kitchen module is 15′ 3″in length, 9′ 0″ in width and approximately 7′ 6″ in height. In someembodiments, the kitchen module includes a plurality of non-structuralself-supporting walls. In some embodiments, the walls of kitchen moduleinclude an internal structure and at least one functional layer 39. Insome embodiments, the functional layer 39 includes thermal and acousticthermal insulation 41 and cement board as finishing layer 40, similar asthe functional layer in wall panels. In some embodiments, the internalstructure is comprised of C-profiles 44 and U-profiles 45. In someembodiments, plumbing fixtures 53 are integrated in the kitchen module.In some embodiments, a plurality of cabinets 54 are integrated in thekitchen module. In some embodiments, the piping 47 correspondent to theinstallation are partly hold in the functional layer and partly fixed inthe installation cabinet. The kitchen module can be applied inconstruction modules, as seen in FIGS. 138-157.

Referring to FIG. 130-133, a “Elevators Doors Module” 69 is provided asa prefabricated element. In some embodiments, the “Elevators DoorModule” element is 15′ 3″ in length, 6″ in width and approximately 8′ 0″in height. In some embodiments, the wall of “Elevators Doors Module”element includes an internal structure and at least one methacrylatelayer 42. In some embodiments, the internal structure is composed ofgalvanized profiles 45. In some embodiments, two elevator doors 55 areintegrated in the internal structure of the “Elevators Doors Module”element. The “Elevators Doors Module” element can be applied inconstruction modules, as seen in FIGS. 138-157.

Referring to FIG. 134-137, a “Core Technical Floor” 70 is provided as aprefabricated element. In some embodiments, the “Core Technical Floor”element is 15′ 3″ in length, 5′ 8″ in width and approximately 1′ 0″ inheight. In some embodiments, “Core Technical Floor” element include asteel frame structure. In some embodiments, the steel frame structure iscomprised of C-profiles 44 and U-profiles 45. In some embodiments, the“Core Technical Floor” element includes a corrugated metal sheet 43 forthe on-site casted concrete in the construction process. The “CoreTechnical Floor” element can be applied in construction module, as seenin FIGS. 138-157.

Referring now to FIGS. 138-147, in the construction module 100X50, wallpanels, wall lintel, trusses/facades, slab panel and prefabricatedelements are connected via rebars and other connections. In someembodiments, vertical rebars in all the element panels are connected tohorizontal rebars from other element panels. In some embodiments,on-site concrete unifies the rebars on different panels and theentirety.

In some embodiments, the present disclosure is directed to a method ofassembling modular panels to produce a building or interior space. Insome embodiments, the modular panels are self-supporting, so individualpanels can be installed one at a time and remain in place while adjacentpanels are installed until a desired size and shape of the building orinterior space is completed. FIGS. 138-147 portray exemplary processesfor connecting panels in the construction module consistent with someembodiments of the present disclosure and as discussed above.

Referring to FIG. 138, once wall panels, wall lintel, trusses/facades,slab panel and prefabricated elements arrive at a building site, wallpanels are first installed on a casted in concrete level 56. Referringto FIG. 139, wall bottom panels 57 would then be installed at the top ofthe casted in concrete level. Rebar connections 81 are placed on top ofthe installed wall bottom panels 57. Referring to FIG. 140,trusses/facades core bottom 59, trusses/facades long bottom 60 andtrusses/facade short bottom 61 panels for the structural facade wouldthen be installed at the end of the installed wall panels. Rebarconnections 81 are placed on top of the installed trusses/facade panels59, 60, 61. Referring to FIG. 141, core prefabricated elements wouldthen be installed. Such elements include “Stair Type 1” element 63,“Stair Type 2” element 64, “Shaft Cabinet” element 65, “Elevators DoorsModule” element 69 and “Technical Floor” element 70. Referring to FIG.142, bottom prefabricated elements would then be casted in concrete. Thepouring of the bottom concrete 71 would connect wall panels,trusses/facades panels and prefabricated core elements into a whole.Connecting rebar 81 would be left on top of the casted in concreteelements to connect the top wall panels, top trusses/facades to thealready installed bottom prefabricated elements.

Referring to FIG. 143, wall top panels 72 would then be installed at thetop of the installed and casted in concrete wall bottom panels. Rebarconnections 81 are placed on top of the installed wall top panels 72.Referring to FIG. 144, trusses/facades core top 74, trusses/facades longtop 75 and trusses/facade short top 76 panels for the structural facadewould then be installed at the end of the installed wall panels and ontop of the bottom trusses/facades panels. Referring to FIG. 145, coreprefabricated elements would then be installed. Such elements include“Stair Type 1” element 63, “Stair Type 2” element 64, “Shaft Cabinet”element 65, “Wall Lintel” element 78 and “Technical Floor” element 70.Referring to FIG. 146, prefabricated slab panels unit 79 would then beinstalled. Referring to FIG. 147, top prefabricated elements would thenbe casted in concrete. The pouring of the top concrete 80 would connectwall panels, trusses/facades panels, prefabricated elements and slabpanels into a whole.

Referring now to FIGS. 148-157, in the construction module 100X34, wallpanels, trusses/facades, slab panel and prefabricated elements areconnected via rebars and other connections. In some embodiments,vertical rebars in all the element panels are connected to horizontalrebars from other element panels. In some embodiments, on-site concreteunifies the rebars on different panels and the entirety.

In some embodiments, the present disclosure is directed to a method ofassembling modular panels to produce a building or interior space. Insome embodiments, the modular panels are self-supporting, so individualpanels can be installed one at a time and remain in place while adjacentpanels are installed until a desired size and shape of the building orinterior space is completed. FIGS. 148-157 portray exemplary processesfor connecting panels in the construction module consistent with someembodiments of the present disclosure and as discussed above.

Referring to FIG. 148, once wall panels, wall lintel, trusses/facades,slab panel and prefabricated elements arrive at a building site, wallpanels are first installed on a casted in concrete level 56. Referringto FIG. 149, wall bottom panels 57, end wall bottom panels 58 would thenbe installed at the top of the casted in concrete level. Rebarconnections 81 are placed on top of the installed wall bottom panels 57and end wall bottom panels 58. Referring to FIG. 150, trusses/facades100X34 bottom 62 for the structural facade would then be installed atthe end of the installed wall panels. Rebar connections 81 are placed ontop of the installed trusses/facade panels 62. Referring to FIG. 151,core prefabricated elements would then be installed. Such elementsinclude “Stair Type 1” element 63, “Stair Type 2” element 64, “ShaftCabinet” element 65, “Bath Module” element 66, “Bath Common Module”element 67, “Kitchen Module” element 68, “Elevators Doors Module”element 69 and “Technical Floor” element 70. Referring to FIG. 152,bottom prefabricated elements would then be casted in concrete. Thepouring of the bottom concrete 71 would connect wall panels,trusses/facades panels and prefabricated core elements into a whole.Connecting rebar 81 would be left on top of the casted in concreteelements to connect the top wall panels, top trusses/facades to thealready installed bottom prefabricated elements.

Referring to FIG. 153, wall top panels 72 and wall top panels w/opening73 would then be installed at the top of the installed and casted inconcrete wall bottom panels. Rebar connections 81 are placed on top ofthe installed installed wall top panels 72 and wall top panels w/opening73. Referring to FIG. 154, trusses/facades core 100X34 top 77 for thestructural facade would then be installed on top of the bottomtrusses/facades panels. Referring to FIG. 155, core prefabricatedelements would then be installed. Such elements include “Stair Type 1”element 63, “Stair Type 2” element 64, “Shaft Cabinet” element 65 and“Technical Floor” element 70. Referring to FIG. 156, prefabricated slabpanels unit 79 would then be installed. Referring to FIG. 157, topprefabricated elements would then be casted in concrete. The pouring ofthe top concrete 80 would connect wall panels, trusses/facades panels,prefabricated elements and slab panels into a whole.

In some embodiments, prefabricated groups of rebars connect wall,lintel, trusses/facades and slab panels. In some embodiments, theon-site casted concrete connects the panels into a whole. In someembodiments, any gaps at the joints between wall, lintel, truss/facade,slab panels and prefabricated elements are filled with polyurethane foamspray, which is fast-solidifying and has thermal insulation properties.In some embodiments, gaps between adjoining panels and/or truss/facadepanels are stuck with adhesive. In some embodiments, construction ofsubsequent floors of a building begins after the underlying floor hassettled. In some embodiments, the upper floor is formed by installingpanels on the internal structures of the previous floor. In someembodiments, upper floors are subsequently constructed in a similarmanner.

1. A system for constructing buildings and interior spaces comprising:at least one wall panel including a wall internal structure, at leastone side layer, and at least one functional wall layer; at least onewall lintel including a lintel internal structure, at least one sidelayer, and at least one functional wall layer; at least one slab panelincluding a slab internal structure, at least one side layer, and atleast one functional slab layer; at least one truss/facade panelincluding a truss internal structure, at least one curtain wall system;at least one interior element including a prefabricated structure and atleast a shaft closet; at least one interior element including aprefabricated structure and at least a prefabricated stair; at least oneinterior element including a prefabricated structure and at least abathroom; at least one interior element including a prefabricatedstructure and at least an integrated kitchen; at least one interiorelement including a prefabricated structure and at least an elevatordoor; at least one interior element including a prefabricated structureand at least a functional layer; wherein said internal wall, lintel,slab and truss/facade structures are configured to connect adjacentpanels, and at least wall, stress and slab panel are temporarilyself-supporting during assembly; wherein said interior elements are selfsupporting and configured to connect to adjacent structure and to eachother.
 2. The system for constructing buildings and interior spacesaccording to claim 1, further comprising at least one functional walllayer positioned in an interior space, defined by said internal wallstructure.
 3. The system for constructing buildings and interior spacesaccording to claim 2, wherein at least one wall panel further includes aformwork and interior structural rebars to be casted in concrete.
 4. Thesystem for constructing buildings and interior spaces according to claim2, wherein at least one functional wall layer includes at least one ofeither an acoustic insulation layer, a finish layer, or combinationsthereof.
 5. The system for constructing buildings and interior spacesaccording to claim 1, further comprising at least one functional walllayer positioned in an interior space, defined by said internal lintelstructure.
 6. The system for constructing buildings and interior spacesaccording to claim 5, wherein at least one wall panel further includes aformwork and interior structural rebars to be casted in concrete.
 7. Thesystem for constructing buildings and interior spaces according to claim5, wherein at least one functional wall layer includes at least one ofeither an acoustic insulation layer, a finish layer, or combinationsthereof.
 8. The system for constructing buildings and interior spacesaccording to claim 1, further comprising at least one functional slablayer, positioned in an interior space and defined by said slab'sinternal structure.
 9. The system for constructing buildings andinterior spaces according to claim 8, wherein at least one slab panelfurther includes a formwork and interior structural rebars to be castedin concrete.
 10. The system for constructing buildings and interiorspaces according to claim 8, further including opposing profiles,wherein at least one functional wall and slab layer is disposed betweensaid opposing profiles, to provide a modular functional layer block. 11.The system for constructing buildings and interior spaces according toclaim 10, wherein said opposing profiles are components of said internalstructure.
 12. The system for constructing buildings and interior spacesaccording to claim 1, further comprising at least one functional layerpositioned in an interior space, defined by said internal truss/facadestructure.
 13. The system for constructing buildings and interior spacesaccording to claim 12, wherein at least one truss further includes aformwork and interior structural rebars to be casted in concrete. 14.The system for constructing buildings and interior spaces according toclaim 12, wherein at least one functional wall layer includes at leastone curtain wall system.
 15. The system for constructing buildings andinterior spaces according to claim 1, further comprising at least oneinterior element, positioned in an interior space and defined by saidinterior element structure.
 16. The system for constructing buildingsand interior spaces according to claim 15, wherein at least one interiorelement includes at least one of either a shaft closet, a prefabricatedstair, a bathroom, an integrated kitchen, an elevator door, a functionallayer, or combinations thereof.